Dodge RAM TRUCK 1500 1995 Service Manual page 947

B R 5.9L ENGINE 9 -103
(4) Install connecting rod bolt protectors on rod
bolts, the long protector should be installed on the
numbered side of the connecting rod.
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Be sure
connecting rod and cylinder bore number are the
same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on crankshaft journal.
(7) The notch or groove on top of piston must be
pointing toward front of engine. The larger chamfer
of the connecting rod bore must be installed toward
crankshaft journal fillet.
(8) Install rod caps. Install nuts on cleaned and
oiled rod bolts and tighten nuts to 61 N-m (45 ft. lbs.)
torque.
(9) Install the oil pan.
(10) Install the cylinder head.
(11) Install the engine into the vehicle.
CRANKSHAFT
A crankshaft which has undersize journals will be
stamped with 1/4 inch letters on the milled flat on
the No.3 crankshaft counterweight (Fig. 6).
FOR EXAMPLE: R2 stamped on the No.3 crank­
shaft counterweight indicates that the No.2 rod jour­
nal is 0.025 mm (0.001 in) undersize. M4 indicates
that the No.4 main journal is 0.025 mm (0.001 in)
undersize. R3 M2 indicates that the No.3 rod journal
and the No.2 main journal are 0.025 mm (0.001 in)
undersize.
Undersize Journal
Identification Stamp
0.025 mm (0.001 inch) (Rod)
0.025 mm (0.001 inch) (Main)
R1-R2-R3 or R4
M1-M2-AA3-M4 or M5
VS LETTERS
2 W
(ROD)
-J—(MAIN)
J9309-52
Fig. 6 Location of Crankshaft Identification
When a crankshaft is replaced, all main and con­
necting rod bearings should be replaced with new
bearings. Therefore, selective fitting of the bearings
is not required when a crankshaft and bearings are
replaced.
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear­
ing cap.
(3) Remove the vibration damper.
(4) Remove the timing chain cover.
(5) Identify bearing caps before removal. Remove
bearing caps and bearings one at a time.
(6) Lift the crankshaft out of the block.
(7) Remove and discard the crankshaft rear oil
seals.
(8) Remove and discard the front crankshaft oil
seal.
INSPECTION OF JOURNALS
The crankshaft connecting rod and main journals
should be checked for excessive wear, taper and scor­
ing. The maximum taper or out-of-round on any
crankshaft journal is 0.025 mm (0.001 inch).
Journal grinding should not exceed 0.305 mm
(0.012 inch) under the standard journal diameter. DO
NOT grind thrust faces of No.3 main bearing. DO
NOT nick crank pin or bearing fillets. After grinding,
remove rough edges from crankshaft oil holes and
clean out all oil passages.
CAUTION: After any journal grind, it is important
that the final paper or cloth polish be in the same
direction a s the engine rotates.
CLEANING
Clean Loctite 518 residue and sealant from the cyl­
inder block and rear cap mating surface. Do this be­
fore applying the Loctite drop and the installation of
rear cap.
INSTALLATION
(1) Lightly oil the new upper seal lips with engine
oil.
(2) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(3) Position the crankshaft into the cylinder block.
(4) Lightly oil the new lower seal lips with engine
oil.
(5) Install the new lower rear bearing oil seal into
the bearing cap with the yellow paint facing towards
the rear of the engine.
(6) Apply 5 mm (0.20 in) drop of Loctite 518, or
equivalent, on each side of the rear main bearing cap
(Fig. 7). DO NOT over apply sealant or allow the
sealant to contact the rubber seal. Assemble bearing
cap to cylinder block immediately after sealant appli­
cation.
(7) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.